The new BKT site at Bhuj-Bhachau road in a village called Paddhar, stretching over a total surface area of 312 acres, epitomizes a vast ocean of resources, precision and quality. It is not one plant, but multiple plants within one. Just the raw material area is so huge that it can store an inventory for couple of months.
One area of the site boasts of an auto chemical bags unit with latest equipment, four of which have been commissioned from Italy. Another part in the site hosts 16 cylos, 13 mixers (three times more than the industry standards) and cooling lines. A lab that houses couple of elaster density tester, three viscometer, three tensometer and six rheometer is one of its kind. “Our researchers, engineers and technicians can boast of having the most advanced equipment for chemical, physical and mechanical testing. The central area in the plant hosts the production house that extends over 72 acres (29 hectares),” reveals Mr. Rajiv Poddar, Joint Managing Director (JMD), BKT. The state-of-the-art R&D center contains an innovative structure, where research on new polymers is conducted to achieve new tread compounds. There are over 18-20 checks that are conducted and club them with the overall start to finish of a tyre manufacturing process, the check count reaches a whopping 1500!
An area of 25 acres, almost 10 hectares, is dedicated to a modern outdoor track where tractors and industrial vehicles equipped with BKT tyres are tested. Together with the R&D area, it constitutes a true masterwork. “We have already received a few requests from other OEMs to test their products on these texting tracks,” claims Mr. D.M. Vaidya, President and Director, Technology, BKT.
Looking at figures and dimensions, Bhuj is a very impressive industrial complex. Yet, it is more than just a prestigious entity for production, research and testing not only for BKT but also for the entire industry. The sprawling site also has a township area, extending over 15 acres (6 hectares), comprises of 406 flats for employees’ families. In addition, there are 90 rooms for university students who have opted to work with BKT, within the scope of an industry-university cooperation project. “Just to name a few of the facilities for the community; there is a large green area with jogging trails, a large recreation center for indoor and outdoor activities, a medical center and a mall,” informs Mr. Poddar.
Notably, the Bhuj plant also has its own fire station with 7 firefighting trucks, 2 ambulances and a smooth firefighting system covering the entire complex, extending over 37 km. “Our intention here in Bhuj, was not to draw a plan for social commitment, but to tangibly materialize and bring to life Corporate Social Responsibility,” beams Mr. Poddar.
In sync with nature
There is another aspect that meets the eye, namely with respect to the environment. The entire production site of Bhuj operates setting new standards in terms of energy efficiency. “In full coherence with BKT’s business model, which has been attentive to environmental aspects includes an area entirely dedicated to plant design and installation, optimizing all site issues related to water and waste management as well as energy autonomy. In Bhuj, our green motto ‘reuse – renew – recycle’ is fully implemented, in terms of respect and care for the environment and efficient use of energy and resources,” explains the Joint MD.
Presently, about 175 MT are rolling off the production lines in Bhuj every day, even though the plant has a capacity of 350 MT per day. As a global specialty tyre supplier, BKT’s strength is the extensive off-highway tyre lineup of over 2,300 products from eight inches to 49 inches tyres. Wide range of sturdy products is the key to BKT’s success, enabling the company to meet the application needs of both end users and vehicle manufacturers.
Ideation to execution
The area, where BKT’s largest and most modern production plant stands today, was previously a desert area with thorny bushes, lacking roads, lack of electricity and water supply, and even herds of wild animals. These were a few road blocks that made it difficult for BKT to find labor force willing to work at Bhuj. “When finally, some manpower was found, it was likewise difficult to keep them; leaving and waiving, unfortunately, happened on an almost daily basis. Starting the project in Bhuj turned out to be a real challenge with henceforth unpredictable and uncertain outcome. The core team never gave up but it was challenging to find motivated workers for other daily jobs initially,” he recalls.
Showing great commitment and dedication, everything was created out of nothing. The first trails turned into large paved roads suitable for transporting people and goods. An over-8-km-long pipeline for drinking water was laid conveying water from the closest water reservoir to the factory, passing through private properties which had required long and patient negotiation. Electricity poles were installed, stretching over a distance of more than 13 km, to finally supply the plant with electric power; canteens and basic service facilities – like toilets and showers – were built for the workers in order to create decent working conditions. After so many odds and adversities, Bhuj plant finally started to take shape and come to life.
Today, the company has its own two water reservoirs and an independent pipeline to ensure abundant water supply. It also boasts of a custom build power plant and a high power generator to safeguard against power failure. The roof top of the plant is such to withstand strong desert winds and the buildings are earthquake resistant to withstand an earthquake tremor of 9 on rector scale.
“The whole idea of building the BKT Bhuj plant stemmed from the thought that everything that we create must be better than the best in the world, be it equipment, infrastructure, or the entire project itself that can make BKT a top name in off highway tyre segment in the world,” avers Mr. Arvind Poddar, Chairman and Managing Director (CMD), BKT. Seconding his CMD, the JMD adds: “We needed a place that is closed to the port, a State Government which is business friendly and above all we needed 300 acres of continuous land to achieve our Chairman’s vision.”
With an investment of approximately $500 million, BKT, a leading manufacturer in the off-highway tyre market in India has certainly marked a new beginning. “Serving both Original Equipment Manufacturers (OEM) and the replacement market, we have focused on specialty segments such as agricultural, industrial vehicles as well as earthmoving, construction, port, mining, and ATV, gardening applications and the Bhuj plant can cater to all the requirements,” concludes Mr. Poddar. Clearly the Bhuj plant is a pioneering of sorts for the tyre industry both in size and scale. Kudos to BKT for the effort!